Bedding and other articles having fill material

ABSTRACT

A bedding article comprises a first quilted panel attached to a second panel so as to enclose an interior. Fill material is disposed in the quilted panel and in the interior.

FIELD OF THE INVENTION

[0001] The present invention relates in general to bedding and other filled articles, such as pillows and comforters, and more particularly to such articles having a common structure adapted for holding fill material to provide support and/or insulation.

BACKGROUND OF THE INVENTION

[0002] Bedding articles, for example, comforters and pillows, often include fill material for body support and/or insulation against the cold. There are used a variety of fill materials including down, feathers, polyester fibers, synthetic foamed enjoyed great popularity for use in bedding articles. However, down requires special considerations when used in bedding articles due to its tendency to shift and/or compact during use which reduces its effectiveness for support and/or insulation.

[0003] In the case of a known comforter, an upper sheet has its peripheral edges attached to the peripheral edges of a lower sheet and a fill material is inserted therebetween. Shifting of the fill material can leave portions of the comforter with only a thin or potentially devoid layer of fill material for insulation. To overcome this problem, lines of stitching attach the upper sheet to the lower sheet to form compartments for holding the fill material. The lines of stitching assist in preventing the shifting of the fill material to retain a more even distribution across the comforter.

[0004] However, this construction can result in the fill material being absent or very thin at the lines of stitching, forming cold spots, whereby the insulating effect of the comforter is compromised. In addition, thin portions may also result from compaction of the fill material, which also detracts from the comfortable feel and insulation of the comforter. Various comforter constructions are known which have addressed these problems. In U.S. Pat. No. 5,987,669 there is known a comforter having an upper sheet and a lower sheet for receiving fill material. Baffles comprising pieces of material are attached in-between the upper sheet and the lower sheet. The baffles prevent the fill material from migrating within the comforter. In U.S. Pat. Nos. 2,960,702 and 1,421,906 there is known a comforter having an upper sheet attached to an intermediate sheet by rows of stitching forming cells for holding fill material. The intermediate sheet is similarly attached to a bottom sheet and also has cells that hold fill material. The stitching is arranged so that the cells of the upper layer are offset from the cells of the lower layer and overlie the there still remains the desire to provide improvements in comforter construction to enhance insulation and eliminate cold spots.

[0005] In the case of a known pillow, an upper and lower sheet are similarly attached about their peripheral edges and a fill material is inserted therebetween. Various fill materials may be selected to alter the support features of the pillow to provide different levels of comfort. For example, a down filled pillow will typically provide for soft support, while the combination of feathers and down will provide for a firmer support. Still further variations in the degree of support can be achieved using various synthetic fill materials, such as polyester fibers, synthetic foam materials and the like.

[0006] Down filled pillows are typically considered the most desirable for their soft feel and comfort level. However, down is also known to be the most expensive of the fill materials and tends to become compacted during use. Although other fill materials are suitable for use in pillows, they do not provide the same degree of soft feel as down, and hence, are less desirable.

[0007] There therefore remains an unsolved need for a common structure for holding fill material which is applicable to a variety of filled articles, and more particularly, to bedding articles that provide improved insulation and/or support properties. Specifically, there is a need for a filled comforter construction that addresses the problems of compacted fill material and/or cold spots such as may occur at stitch lines; and a filled pillow construction that maintains a soft outer layer of fill material for enhanced support independent of the characteristics of the fill material used throughout the remainder of the pillow.

SUMMARY OF THE INVENTION

[0008] The various described filled articles according to the embodiments of the invention provide different benefits using a common structure depending on the use of the filled article. The filled article may comprise a number of different articles, including bedding articles, such as pillows and comforters. In a pillow the structure of the invention provides enhanced user support among other benefits, while in a comforter the structure provides enhanced insulation among other benefits.

[0009] According to one aspect of the present invention, a filled article includes a first quilted panel and at least one second panel attached thereto so as to form an interior region therebetween. A first fill material is disposed in the first quilted panel and a second fill material is disposed in the interior region. The quilted panel tends to hold the first fill material to prevent significant shifting. In the case of a pillow, the first quilted panel provides improved support, while in the case of a comforter, the first quilted panel provides improved insulation.

[0010] The interior region provides an additional layer of fill material to add thickness for support and/or insulation to the article. In embodiments incorporating a down fill material, the quilted panel tends to prevent significant shifting of the down. The quilted panel in the case of a comforter also adds structure and depth to the filled article to provide an additional layer of insulation. In the case of a pillow, the quilted panel provides a soft comfortable outer layer which can have fill material independent of the type of fill material used in the interior region for additional user support.

[0011] In a further aspect of the present invention, a comforter or pillow is constructed from a first quilted panel attached to a second quilted panel. The quilted panels are attached together about their periphery using a side panel to form an interior region therebetween. A first fill material is disposed in the first and second quilted panels and a second fill material is disposed fin the interior region. The quilted panels in the case of a comforter provides additional layers of insulation. The second fill material in the interior region provides a further insulation layer and tends to insulate thin areas that may have formed in the outer quilted panels. In the case of a pillow, the quilted panels provide soft comfortable outer layers providing enhanced user support. The filled interior region also provides support which, depending on the fill material, can vary the firmness of the pillow independent of the outer quilted panels.

[0012] In certain preferred embodiments, the comforter further includes at least one baffle construction disposed between the outer panels. The baffle construction may be attached to the panels at a plurality of locations. The baffle desirably forms pockets subdividing the interior region. The pockets desirably spans some of the stitching lines which are used to form the quilted panels.

BRIEF DESCRIPTION OF THE DRAWINGS

[0013] These and other features, aspects and advantages of the present invention will become better understood with regard to the following detailed description, appended claims, and accompanying drawings in which:

[0014]FIG. 1 is a top-right perspective view of a pillow in accordance with an embodiment of the invention;

[0015]FIG. 2 is a front elevation of a pillow in accordance with the embodiment of FIG. 1;

[0016]FIG. 3 is a partial top-right perspective view of the pillow in accordance with the embodiment of FIGS. 1 and 2;

[0017]FIG. 4 is a cross-sectional view of a pillow in accordance with the embodiment of FIGS. 1-3;

[0018]FIG. 5 is an exploded view of a quilted panel for a pillow in accordance with the embodiment of FIGS. 1-4;

[0019]FIG. 6 is an exploded view of a pillow in accordance with the embodiment of FIGS. 1-5;

[0020]FIG. 7 is an exploded view of a comforter in accordance with a further embodiment of the invention;

[0021]FIG. 8 is a cross-sectional view of a comforter in accordance with the embodiment of FIG. 7;

[0022]FIG. 9 is an exploded view of a quilted panel in accordance with the embodiment of FIGS. 7-8; and

[0023]FIG. 10 is a top-right perspective view of a baffle system for use in a comforter in accordance with the embodiment of FIGS. 7-9.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0024] In describing the preferred embodiments of the present invention, specific terminology will be resorted to for the sake of clarity. However, the invention is not intended to be limited to the specific terms so selected, and is to be understood that each specific term includes all technical equivalence which operate in a similar manner to accomplish a similar purpose. Any reference to directions such as upper, lower, top and bottom are intended to be relative to the bedding article itself and not to any gravitational frame of reference.

[0025] The present invention provides a common structure for the design of bedding articles such as comforters and pillows. The structure in one embodiment provides two outer layers which are preferably quilted, and an interior region. The outer layer in the case of a comforter provides additional layers of insulation to enhance warmth. The interior region provides a third layer of insulation for additional warmth, and to reduce the effects of thin or compacted fill material in the outer layers. In the case of a pillow, the outer layers provide a soft enhanced supporting surface for the user. The interior region provides another support region which can have fill material of a different firmness than the fill material in the outer quilted layers.

[0026] In accordance with one exemplary embodiment of the invention as shown in FIGS. 1-6, a pillow 10 includes an upper quilted panel 12 and a lower quilted panel 14. Each of the quilted panels are formed from an outer sheet 16 and an inner sheet 18 joined together at their outer edges. Each quilted panel also includes stitching lines 20, including rim lines 22 that extend around the peripheral edge 13 of the quilted panel in spaced relationship. The rim lines 22 form a rim 30 that extends around the peripheral edge 13 of the quilted panel. The stitching lines 20 include longitudinal quilting lines 24 and lateral quilting lines 26 forming individual compartments 28 located inwardly of the peripheral rim 30. Each of the quilted panels carries a gusset 31 that extends around the peripheral edge 13 beneath the rim 30. The gusset 31 is attached to the quilted panel at the rim lines 22 thereof.

[0027] The upper quilted panel 12 is attached to the lower quilted panel 14 by a side panel 32 interposed between the quilted panels. In the embodiment shown, the side 40 of the pillow 10 includes the side panel 32 having an upper edge 34 and a lower edge 36. The upper edge 34 is attached to the periphery 33 a of the gusset 31 a on the upper quilted panel 12 and the lower edge 36 is attached to the periphery 33 b of the gusset 31 b on the lower quilted panel 14. The interior 42 is therefore enclosed by the upper quilted panel 12, lower quilted panel 14 and side 40 as best shown in FIG. 4. The side panel 32 may comprise one or more pieces of material. In the embodiment shown, the side panel 32 comprises a single strip of material having a first end 33 and a second end 37 attached to one another.

[0028] The outer sheet 16 comprises a piece of material with an outer edge 17. The outer edge 17 is joined to an outer edge 49 of the inner sheet 18. The inner sheet 18 comprises a liner material 46, the gusset 31 attached to the perimeter 47 of the liner, and a bottom rim portion 48. The bottom rim portion 48 is attached to the gusset 31 along joining lines 51 spaced from the edges of the gusset 31 and the bottom rim portion. The bottom rim portion 48 forms the outer edge 49 of the inner sheet 18. The shape of the outer sheet 16, as well as the inner sheet 18, is selected according to the desired shape of the finished pillow 10.

[0029] The gusset 31 and bottom rim portion 48 may be formed of one or more strips of material sewn together. The liner 46 preferably comprises a single piece of material. The liner 46 will be disposed on an interior side of the pillow and will not be visible to the user. Thus, the liner 46 may be any material, whereas the other pieces of material used in making the pillow may comprise other materials, but preferably, materials that are pleasing in appearance and comfortable for the user.

[0030] The rim 30 may have fill material disposed between the outer sheet 16 and inner sheet 18, i.e., between the peripheral edge 13 and rim lines 22. The quilted panels have quilting lines, which may be made in a variety of patterns, but preferably do not extend into the rim 30. The particular pattern for the quilting lines is a matter of design choice. The outer sheet and inner sheet may be attached to one another at a plurality of locations to form a quilted panel without using lines of stitching. Both the upper quilted panel 12 and lower quilted panel 14 may have the construction discussed above. However, the invention also contemplates the use of a single quilted panel for forming one side of the pillow and one or more pieces of material attached to the quilted panel for enclosing the interior 42.

[0031] In a preferred embodiment, by way of example only, the fill material of the upper and lower quilted panels 12 and 14 and the fill material 44 in the interior 42 both include down feathers or a combination thereof. However, the invention encompasses other fill materials provided in the quilted panels and the interior 42 of the pillow 10. In addition, different fill materials may be used in each of the quilted panels and a fill material may be used in the interior 42 that is different from the fill materials in each quilted panel.

[0032] The fill material may also include any material commonly used to fill pillows, cushions, quilts, or comforters. Loose or non-loose fill materials, such as batting may be used. Such materials may include natural fill materials, such as feathers, down and combinations thereof, or synthetic fill materials, such as polymers, fibers of various types, foam materials, including foam rubber and urethane foams, and combinations of the foregoing. Accordingly, the fill material used in the interior region may be selected to control the firmness of the pillow.

[0033] The pillow 10 may have a regular or irregular shape, including any polygon, circle or oval, and may comprise any size such as standard, queen or king-sized pillow. The pillow may be used wherever the user desires a cushion for support or for show. The materials used to form the panels and the sides of the pillow may comprise cotton, polyester, or any other natural or man-made material used for bedding. The material preferably comprises a material that will prevent the escape of down or feathers when used as the fill material. The materials may comprise any woven or non-woven material. The parts of the pillow are attached by sewing, utilizing a thread or other string. The thread may comprise any natural or man-made material, such as cotton or polyester. The parts of the pillow may also be attached using adhesive materials.

[0034] It may be preferred to hide as many of the seams as possible in attaching the pieces of material together for the pillow. The pieces may be stitched together, except for a small opening. Then, the pieces are turned right side out, hiding most of the seams. The opening may be used for insertion of fill material and then closed. Such techniques are well known in the art.

[0035] The outer quilted panels of the pillow enable the use of fill material such as down to provide a soft comfortable surface for enhanced support. The interior 42 of the pillow may be filled with other less expensive fill materials to provide different levels of pillow firmness. Thus, a firm pillow can be constructed from less expensive fill materials, while providing a soft down filled outer layer for additional support and comfort. The quilted panels also provide a filled layer in which the fill material is not subject to shifting. This prevents loss of thickness in the pillow and loss of support. In down filled pillows, in particular, the quilted panels also provide thickness for support and avoid the thin, insubstantial feel of a down pillow in which the down has become significantly compacted.

[0036] In another embodiment, a bedding article is similarly constructed. A comforter 110 is shown in FIGS. 7-10 having an upper quilted panel 112 and a lower quilted panel 114 attached to one another to form an interior 144. It is contemplated that one of the quilted panels may be a single material layer to form the interior region with the other quilted panel. Each of the quilted panels are constructed as discussed above in connection with the pillow, except that the quilted panels, and their constituent parts, are sized for a comforter. The comforter may be sized for lying on a bed and may be used wherever the user desires a comforter for warmth. The comforter can have any standard size, such as a standard, twin, king or queen size, or any non-standard size.

[0037] The comforter 110 has quilted panels comprising an outer sheet 116 attached to an inner sheet 118. The inner sheet 118 comprises a gusset 130 and bottom rim portion 148 attached to the perimeter 147 of a liner 146. The bottom rim portion 148 is also attached to the gusset 130 at joining lines 151. The bottom rim portion 148 is attached to the outer sheet 116. The quilted panels have quilting lines, fill material and rim lines as discussed above. The sides of the comforter 110 include gusset s for each of the upper quilted panel 112 and lower quilted panel 114, and a side panel 132. The gusset s and side panel are attached so that the side panel is interposed between the gusset s. For the comforter 110, the side panel 132 is relatively short in height and it may be desirable to fill the comforter less densely, as compared to the pillow 10. This allows the comforter 110 to be more compliant having three layers of fill material and more easily adjusted by the user during use of the comforter.

[0038] In a preferred embodiment, the comforter includes a baffle system 160 comprising a plurality of baffles attached between the upper quilted panel 112 and the lower quilted panel 114. The baffles form pockets 161 between the quilted panels, subdividing the interior 142 and preventing shifting of the fill material. Each baffle has a bottom edge 166 that is attached to the liner of the lower quilted panel 114. Each baffle also has a top edge 168 that is attached to the liner for the upper quilted panel 112. The baffles may be arranged in a wide variety of patterns including any regular or irregular geometric shapes. In the embodiment shown, the baffles include longitudinal baffles 162 and lateral baffles 164 extending transversely to the longitudinal baffles 162 so that a grid is formed. In addition, the embodiment shown has longitudinal baffles 162 comprising pieces of material with a length about equal to the length of the liner 146 and attached to the liner 146 for each quilted panel. The lateral baffles 164 comprise pieces of material that extend between each of the longitudinal baffles 162 and are attached thereto. In other embodiments, the pieces of material used to form the baffles may have other shapes and sizes.

[0039] The interior 142 of the comforter is filled with a fill material using techniques known in the art. The fill material may include any of the fill materials discussed above. At least some of the baffles desirably include a small hole or slit for filling the pockets 161. A fill machine may be used to blow fill material into each pocket 161. The fill material includes a spout that is inserted into the small hole or slit for filling the pockets 161. Each quilted panel may comprise a different fill material and the fill material of the interior 142 may also be different from the fill material of each quilted panel. If desired, each pocket 161 may hold a different fill material.

[0040] In a preferred embodiment, the plurality of baffles forms pockets 161 that span at least some of the stitching lines 120 of the upper quilted panel 112 and lower quilted panel 114. As best seen in FIG. 8, the baffle system 160 comprises pieces of material attached to the quilted panels at some but not all of the stitching lines 120. Thus, each pocket 161 preferably spans at least one stitching line 120 on an upper quilted panel, lower quilted panel, or both. The baffle system 160 may comprise, for example, baffles attached to every other stitching line in both directions.

[0041] The quilted panels may comprise an outer sheet attached to an inner sheet at a plurality of locations, without using lines of stitching. In certain embodiments, pockets span at least one stitching line of a quilted panel so that the fill material 144 is interposed between the stitching lines 120. This insulates the stitching lines 120 against forming cold spots. In the embodiment shown in FIG. 8, the stitching lines 120 of the upper quilted panel 112 are aligned with the stitching lines 120 of the lower quilted panel 114. However, in other embodiments, the stitching lines of one quilted panel may be offset from the stitching lines of another quilted panel. In further embodiments of the invention, the filled interior of the comforter or a second panel provides further insulation and addresses the problem of cold spots, as well as providing other benefits.

[0042] In certain preferred embodiments, a bedding article, such as a pillow or comforter, is formed from an upper quilted panel attached to a lower quilted panel directly, either at the peripheral edge of each quilted panel, or at a rim line for the quilted panels or another location. In a further embodiment, the upper quilted panel is attached to the lower quilted panel by a side panel formed from one or more pieces of material, without the gusset discussed above. In addition, an embodiment of the invention comprises a bedding article with a single quilted panel attached to at least one other panel so as to enclose an interior. The other panel need not comprise a quilted panel. Such a bedding article may incorporate one or more baffles for holding fill material within the interior. For example, a pillow or other cushion may include baffles. Baffles are not required, however, and other embodiments of the invention include fill material in the interior for insulation against cold spots, or other benefits. In other embodiments, a bedding article comprises a first quilted panel and a second quilted panel and each of the quilted panels have a different number and/or pattern of compartments. Each of the quilted panels may have a different shape or size. Either or both quilted panels may comprise a rim or the rim may be omitted. In the embodiments discussed above, the quilted panels are formed by stitching lines. However, lines of stitching need not be used. In other embodiments, the quilted panels are formed by stitching the outer sheet to the inner sheet at a point or location, so that the compartments are not entirely closed. In addition, means other than stitching may be used. Furthermore, embodiments including baffles need not form entirely closed pockets.

[0043] It is therefore understood that numerous modifications may be made to the illustrative embodiments and that other arrangements may be devised without departing from the spirit and scope of the present invention as set forth in the appended claims. 

We claim:
 1. A filled article comprising: a first quilted panel; a second quilted panel; and at least one side panel attached to the first quilted panel and the second quilted panel so as to form an interior between the first quilted panel and second quilted panel.
 2. The article of claim 1, further comprising a first fill material in the first quilted panel.
 3. The article of claim 2, wherein the at least one side panel is attached to the first quilted panel and the second quilted panel so that the at least one side panel is interposed between the first quilted panel and second quilted panel.
 4. The article of claim 2, wherein the first quilted panel has a peripheral edge and at least one stitching line, including a stitching line spaced from the peripheral edge of the first quilted panel so as to form a rim in the first quilted panel.
 5. The article of claim 4, wherein the rim has the first fill material disposed therein.
 6. The article of claim 2, further comprising a second fill material disposed in the interior.
 7. The article of claim 6, wherein the first fill material and the second fill material comprise down.
 8. The article of claim 1, wherein the first quilted panel comprises an outer sheet attached to an inner sheet at a plurality of locations.
 9. The article of claim 8, wherein the outer sheet and the inner sheet are attached to one another so as to form compartments.
 10. The article of claim 8, wherein the inner sheet comprises a liner and a bottom rim portion attached to the liner.
 11. The article of claim 9, wherein the bottom rim portion is attached to an outer edge of the outer sheet.
 12. A filled article comprising: a casing enclosing an interior having a first fill material; the casing including first compartments disposed outwardly of the first fill material, the first compartments enclosing a second fill material; at least one of the first fill material and second fill material being selected from the group consisting of down and feathers.
 13. A filled article comprising: a first quilted panel; at least one second panel attached to the first quilted panel so as to form an interior between the at least one second panel and the first quilted panel; and a first fill material in the first quilted panel and a second fill material in the interior.
 14. The filled article of claim 13, wherein at least one of the first fill material and second fill material comprises down.
 15. The filled article of claim 13, wherein the first quilted panel forms first compartments for holding the first fill material.
 16. The filled article of claim 15, wherein the at least one second panel comprises a second quilted panel having second compartments enclosing a third fill material.
 17. The filled article of claim 13, wherein the first quilted panel comprises a peripheral edge and a rim adjacent the peripheral edge.
 18. The filled article of claim 17, wherein the rim encloses some of the second fill material.
 19. The filled article of claim 13, wherein the first quilted panel and second quilted panel are attached to one another by a side panel disposed between the first quilted panel and second quilted panel.
 20. The filled article of claim 13, wherein the first fill material and the second fill material comprise the same type of fill material.
 21. The filled article of claim 13, wherein said filled article comprises a pillow.
 22. The filled article of claim 13, further comprising at least one baffle disposed between the first quilted panel and the at least one second panel.
 23. The filled article of claim 22, wherein the first quilted panel comprises an outer sheet attached to an inner sheet at a plurality of locations and wherein the at least one baffle is attached to the first quilted panel at at least some of the locations.
 24. The filled article of claim 22, wherein the at least one baffle forms pockets subdividing the interior.
 25. The filled article of claim 24, wherein the outer sheet is attached to the inner sheet by stitching lines and at least one of the pockets spans at least one of the stitching lines.
 26. The filled article of claim 13, wherein the at least one second panel comprises a second quilted panel attached to the first quilted panel so as to form the interior.
 27. The filled article of claim 24, wherein the at least one second panel comprises a side panel attached to the first quilted panel and the second quilted panel so that the side panel is interposed between the first quilted panel and second quilted panel.
 28. The filled article of claim 13, wherein the first quilted panel comprises a peripheral edge and at least one stitching line spaced from the peripheral edge so as to form a rim.
 29. The filled article of claim 28, wherein the rim encloses some of the first fill material.
 30. The filled article of claim 13, wherein said filled article comprises a comforter.
 31. The filled article of claim 30, wherein the first fill material comprises the same type of fill material as the second fill material.
 32. The comforter of claim 31, wherein the first fill material and the second fill material comprises down.
 33. The comforter of claim 26, wherein the first quilted panel comprises first stitching lines and the second quilted panel comprises second stitching lines.
 34. The comforter of claim 33, further comprising at least one baffle attached to the first quilted panel at one of the first stitching lines and to the second quilted panel at one of the second stitching lines. 